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Service Manual
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Chapter 3 - Technical DataTechnical data ................................................................................................................................................... 3-3
1 Machine data .................................................................................................................................... 3-31.1 General................................................................................................................................... 3-31.2 Engine .................................................................................................................................... 3-31.3 Splitterbox............................................................................................................................... 3-41.4 Hydraulic system .................................................................................................................... 3-4
2 Adjustment procedure 9250.............................................................................................................. 3-72.1 Initial adjustment..................................................................................................................... 3-72.2 Working pumps adjustment .................................................................................................... 3-112.3 Primary and secondary valves adjustment............................................................................. 3-142.4 Ladder and service trap adjustment ....................................................................................... 3-182.5 Swing adjustment ................................................................................................................... 3-182.6 Cooling adjustment................................................................................................................. 3-20
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Machine data
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3 Technical data
3.1 Machine data
3.1.1 General
3.1.2 Engine
Machine weight backhoe attachment t
Machine weight shovel attachment t
Length without attachment mm
Width of the undercarriage (... mm track pads) mm
Height without attachment mm
Tail swing mm
Ground clearance mm
Digging force / breakout force (backhoe attachment) kN
Crowd force at ground level / max. crowd force / breakout force(shovel attachment)
kN
Trademark CUMMINS
Model QSK 45
Type 12 cylinders, V-engine
Rating at nominal per SAE J 1995 kW 960 (1304 HP)
Nominal speed RPM 1800
Idle speed RPM
High idle RPM
Maximal torque (at 1500 RPM) mN 5800
Stroke volume l (cu, in) 45 (2745)
Bore / stroke mm
Oil quantity
Oil change intervals hrs 250 or chart method
Oil viscosity (above -25°C / -13°F)
Firing order 1R - 6L - 5R - 2L - 3R - 4L6R - 1L - 2R - 5L - 4R - 3L
Technical data
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3.1.3 Splitterbox
3.1.4 Hydraulic system
3.1.4.1 Main circuit
Valve adjustment intake / exhaust mm 0,36 / 0,81
Maximum supply fuel flow kg / h
Diesel fuel tank capacity l
Trademark
Type
Oil quantity l
Oil viscosity SAE 90 or SAE 80W-90
Hydraulic pumps type (2x) A20VSO520 + (1x)A11VLO260 at 1800 RPM
Pumps output kW 797,23 (1083 HP)
Max flow l/min 2122,42
Regulation begin at nominal engine power bar 214,11
Max. operating pressure (primary relief valves) bar 320±5
Regulation end (pressure cut off) bar 300±5
Secondary pressure bar 380±10
Hydraulic oil quantity when maximum level in the tank l
Hydraulic oil quantity to change l 3650
Hydraulic oil change intervals hrs 2000
Filter change intervals hrs first at 500 / every 1000
Control valves for backhoe attachment type
Control valves for shovel attachment type
Hydraulic cylinders
Boom cylinder Ø piston / Ø rod / stroke (backhoe attachment) mm 320 / 220 / 2850
Boom cylinder Ø piston / Ø rod / stroke (shovel attachment) mm
Stick cylinder Ø piston / Ø rod / stroke (backhoe attachment) mm 260 / 180 / 2250
Crowd cylinder Ø piston / Ø rod / stroke (shovel attachment) mm
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Machine data
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3.1.4.2 Swing circuit
3.1.4.3 Servo control oil circuit
3.1.4.4 Cooling circuit
Bucket tilt cylinder Ø piston / Ø rod / stroke mm 230 / 160 / 1950
Shovel tilt cylinder Ø piston / Ø rod / stroke mm
Shovel flap cylinder Ø piston / Ø rod / stroke mm
Closed circuit
Swing pump type (2x) A4VG 125 (2820 RPM)
Swing pump design Double swash plate type axialpiston pumps
Swing pump output kW (2x) 220 (2x 299 HP)
Max. displacement cm³ 2x 125
Max. flow l/min 705
Max. operating pressure bar 350
Secondary pressure - swing circuit bar 400
Hydraulic pump type HY / Z GS 11 / 22.5 (2820RPM)
Hydraulic pump design Geared pump
Control oil pump output kW
Max. flow / servo l/min 63
Servo pressure bar
Oil cooler pump type A11VO75 (2226 RPM)
Oil cooler pump design variable flow axial pistonpump
Oil cooler pump output kW 110 (149 HP)
Oil cooler pump volume cm³ 74
Oil cooler pump flow l/min 280
Oil cooler motor volume l/min (FMF90)
Water cooler pump type A11VO75 (2226 RPM)
Water cooler pump design variable flow axial pistonpump
Water cooler pump output kW 110 (149 HP)
Technical data
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Water cooler pump volume cm³ 74
Water cooler pump flow l/min 280
Water cooler motor volume cm³ (FMF90)
Splitterbox oil cooling pump type HYZGS11/28
Splitterbox oil cooling pump design Geared pump
Splitterbox oil cooler pump volume cm³
Splitterbox oil cooler pump flow l/min 79
Splitterbox cooling pump pressure bar
Hydraulic rotary connection type
Service Manual
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Adjustment procedure 9250
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3.2 Adjustment procedure 9250
Fig. 0-1 Pumps installation
3.2.1 Initial adjustment
3.2.1.1 Pre-requirement
Nominal value Measured value
Adjusted value
Hydraulic tank pressurisation 0 bar
Minimal RPM on the display 800 + 50 RPM
Nominal RPM on the display 1800 ±10 RPM charged
Maximal RPM on the display 1870 ±20 RPM
Servo pressure 55 bar
Technical data
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Adjustment of servo pressure
Fig. 0-2 Servo unit
• Gauge on P (60 bar).• Engine at 1800 ±50 RPM.• Adjust the screw 9 on the servo unit so to obtain .........................................................P = 55 +3 bar
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Adjustment of swing brake
Fig. 0-3 Servo unit
Adjustment :
• Gauge on A5 (60 bar).• Engine at 1200 ±50 RPM.• Unplug the valve Y7 at E1038.• Adjust the screw 6 on the servo unit so to obtain .........................................................P at A5 = 30 ±2 bar• Plug back the valve Y7.
Check of the good working of the pump control box
Fig. 0-4 Working pumps
Nominal value Measured value
Adjusted value
Swing brake (valve Y7 on the servo unit) open for 30 bar 30 bar
Technical data
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Check of the pressure Pst : use a 60 bar gauge (precision : ±0,6 bar).
Initial adjustment
Fig. 0-5
Installation of the pump control box for R/P 9250Connect the control box (Ident. Nr.) to the connectors XT103 and XT104 in the switching box E1005 of the cab.
Pre-adjustment on the display• Install Green Access Key at X30 or X31 on ESP01 (A1001) cards.• Enter into «SET PUMPS» Menu :
Enter in «I3» and thanks to the arrows up and down, set EV1, EV2 at 100%.
Enter in «I4» and thanks to the arrows up and down, set EV1, EV2 at 40%.
Position Pst requi-red (bar)
Measured value Procedure if the required value is not reached
0 <10 Can not be modified
1 15±2 Adjustment of I4 on the display (from EV1 to EV2) at 40%I4 adjusted at : _ _ % = _ _ bar
2 >20 Adjustment of the maximal current in the BST (U16) at 650 mA
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3.2.2 Working pumps adjustment
3.2.2.1 Pumps P1 and P2
Fig. 0-6 Servo unit
Fig. 0-7 Working pumps P1 and P2
For the pumps adjustment, the oil temperature value must be : 55 +5°C.
Adjustment of switching point for flow controlTool requirement : open-end wrench 13 and 19.
• Gauge on P (60 bar) ............................................................................................................... P = 55 bar• Gauge on Mst (60 bar).• Gauge on Pst (60 bar).• Engine at 1800 ±50 RPM, control box on position 1 :Angle indicator of the pump7,5 ±2,5°• Adjust the screw DW so to obtain......................................................................................Mst = 25 bar
P - Mst = 30 ±2 bar
Technical data
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Hydraulic adjustment for QminTool requirement : open-end wrench 46 and 30.
• Gauge on P (60 bar) ...............................................................................................................P = 55 bar• Gauge on Mst (60 bar).• Gauge on Pst (60 bar).• Engine at 1800 ±50 RPM, control box on position 0 :• Unplug the valve Y3 corresponding to the pump to adjust.• Adjust the screw Hmin so to obtain .........................................................................10 bar < Mst < 15 bar• Plug back the valve Y3 corresponding to the pump to adjust.
Hydraulic adjustment for QmaxTool requirement : imbus wrench 3.
• Gauge on P (60 bar) ...............................................................................................................P = 55 bar• Gauge on Mst (60 bar).• Gauge on Pst (60 bar).• Engine at 1800 ±50 RPM, control box on position 2 :• Unplug the valve Y3 corresponding to the pump to adjust.• Adjust the screw Hmax so to obtain ..................................................................................Mst = 45 ±3 bar• Plug back the valve Y3 corresponding to the pump to adjust.
Adjustment of the power regulatorTool requirement : open-end wrench 13 and 19.
• Unplug the valve Y4.....................................................................................................................XLR = 0• Gauge on P (60 bar) ...............................................................................................................P = 55 bar• Gauge on Mst (60 bar).• Gauge on Pst (60 bar).
Pump P1 Pump P2
Nominal value Measured value
Adjusted value Nominal value Measured
valueAdjusted
value
Pst = 15 ±2 bar Pst = 15 ±2 bar
Mst = 25 bar Mst = 25 bar
ðP = P - Mst = 30 ±2 bar ðP = P - Mst = 30 ±2 bar
Pump P1 Pump P2
Nominal value Measured value
Adjusted value Nominal value Measured
valueAdjusted
value
Pst < 10 bar Pst < 10 bar
10 bar < Mst < 15 bar 10 bar < Mst < 15 bar
Pump P1 Pump P2
Nominal value Measured value
Adjusted value
Nominal value Measured value
Adjusted value
Pst >20 bar Pst >20 bar
Mst = 45 ±3 bar Mst = 45 ±3 bar
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Adjustment procedure 9250
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• Engine at 1800 ±50 RPM, control box on position 2 :• Turn in the screw LR all the way in order to have the lowest pressure Mst.• Slowly turn out the screw LR until the pressure Mst begins to increase.• Search the point at which the pressure decreases.• Plug back the valve Y4.
Adjustment of the pressure regulator• Engine at 1800 ±50 RPM• Loosen the screw DR one turn• Adjust the corresponding primary pressure relief valve at 300 bar (see procedure). Don’t plug X82 (on
E1005).• Gauge on MB (use the same gauge as before for the primary valve).• Tighten the screw DR until the pressure MB increases................................................DA = 300 +5 bar• Do this adjustment for each working pump.• Plug back the connector X82.
3.2.2.2 Pump P3
Fig. 0-8 Working pump P3
For the adjustment of the working pump P3, don’t unplug the valve Y4_2.
Beginning of regulation• Gauge on M (600 bar).• Gauge on M1 (600 bar).• In the display menu «power test» register ........................................................................................ 0 %Information : on the valve Y4_2.....................................................................................................300 mA• Start the engine.
Pump P1 Pump P2
Nominal value Measured value
Adjusted value
Nominal value Measured value
Adjusted value
Pst >20 bar Pst >20 bar
Nominal value Measured value Adjusted value
DA 300 bar
Technical data
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• Engine at 1800 ±50 RPM.• Adjust the primary pressure relief valve on VB3 so to obtain ...................................................... 130 bar• At the pump regulation begin, the pressure at M1 pass from 0 to 70 bar.• If the beginning of the regulation isn’t correct, adjust the screw opposed to the solenoid valve.• Readjust the primary relief valve to the prescribed value.
Cut off adjustment• Engine at 1800 ±50 RPM.• Turn counterclockwise one or two turns the screw of the pressure regulator.• Discharge primary pressures on VB3 at ......................................................................................305 bar• Gauge on M (600 bar).• Gauge on M1 (600 bar).• Fully retract the stick cylinders supplied by the pump and maintain the joystick actuated.• Slowly turn the screw clockwise on the regulator while observing the pressure at gauge M1 drop to 150
bar• Readjust the primary relief valve to the prescribed value.
3.2.3 Primary and secondary valves adjustment
Fig. 0-9 Control valve block
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Adjustment procedure 9250
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Fig. 0-10 test points travel motors
3.2.3.1 Secondary valves adjustmentBefore adjusting the valves, unplug the connector X82 to inactivate the proximity switches. After adjusting, re-connect X82.
Travel adjustment• Disconnect brake hoses and blank off the ports Br ext.• Tighten completely the primary valves and loosen of a quarter turn.• Gauge on MA and MB (600 bar).• Engine at 1500 ±50 RPM.• Actuate the movement corresponding to the valve and maintain actuated.• Adjust the valve so to obtain....................................................................................MA = MB = 380 bar• Do the same procedure for the other side.• Reconnect brake hoses on the ports Br ext.
Attachment adjustment• Gauge on P (600 bar).• Tighten completely the primary valve on the valve block and loosen of a quarter turn.• Engine at 1500 ±50 RPM.• Do the movement corresponding to the secondary valve and maintain it actuated.• Adjust the screw 30 so to obtain............................................................................................. P = 380 bar• Do the same procedure for all the secondary valves of all the valve blocks (VB1, VB2 and VB3).
Movement Nominal value (bar)
Measured value Adjusted value
VB1 VB2 VB3 VB1 VB2 VB3
BoomUP 380 +20
DOWN 380 +20
Technical data
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StickOUT 380 +20
IN 380 +20
BucketOUT 380 +20
IN 380 +20
ShovelOUT
380 +20
140 +20
IN 380 +20
TrapCLOSE 380 +20
OPEN 340 +20
Translation leftUP 380 +20
DOWN 380 +20
Translation rightUP 380 +20
DOWN 380 +20
Translation left and right
380 +20
380 +20
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Adjustment procedure 9250
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3.2.3.2 Primary valves adjustment
Simple primary values adjustment
Fig. 0-11 Control valve installation
• Gauge on P (600 bar).• Engine at 1800 ±50 RPM.• Extend the boom or stick and maintain actuated.• Adjust the valve so to obtain................................................................................................... P = 320 bar• Do the same procedure for the other simple primary valve.
Nominal value (bar)
Measured value Adjusted value
VB1 VB2 VB3 VB4 VB1 VB2 VB3 VB4
Single stage primary valve 320 +10
Technical data
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3.2.4 Ladder and service trap adjustment
Fig. 0-12 Ladder and service trap adjustment
• Gauge on test point (600 bar).• Actuate the down motion for the ladder or for trap.• When the ladder or the trap has reached its low position, continue to press the button.• Adjust PRV to obtain................................................................................................Test point = 110 bar
3.2.5 Swing adjustmentSecondary relief valve (400 bar) are not adjustable. If necessary, command a new cartridge.
Nominal value (bar) Measured value Adjusted value
Test point 110
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Fig. 0-13 Swing adjustment
3.2.5.1 Replenishing pressure• Gauge on G (60bar).• Engine at 1800 ±50 RPM.• Adjust the screw X so to obtain .............................................................................................. G = 30 bar• Do the same procedure for the both swing pumps (P5.1 and P5.2).
3.2.5.2 Swing working pressure• Gauge on MA and MB (600 bar).• Engine at 1800 ±50 RPM.• Fully actuate the swing joystick to the left.• Adjust the screw DR so to obtain.......................................................................................MA = 320 bar• Fully actuate the swing joystick to the right ................................................................................. MA = MB
Nominal value (bar) Measured value Adjusted value
Replenishing pressureP5.1 30
P5.2 30
Nominal value (bar) Measured value Adjusted value
Swing working pressure 320
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3.2.6 Cooling adjustment
Fig. 0-14 Cooling pumps
• Run the diesel engine at high idle.• Disconnect the regulation valve Y10.1 for pump P6.1 (Y10.2 for pump P6.2).• Gauge on M (600 bar).• Adjust RDA1 (or RDA2) to obtain ......................................................................................M = 250 bar• Check the way of rotation of the fan : flow from outside to inside.
Nominal value Measured value Adjusted value
High pressure M (P6.1) 250 bar
High pressure M (P6.2) 250 bar
Oil cooling fan speed 1200 RPM
Water cooling fan speed 1150 RPM
Recommended